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2002 FXD frame off build

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Old May 13, 2020 | 04:34 AM
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Default 2002 FXD frame off build

Hey what is up everyone. Wanted to start a thread, mostly to keep myself accountable. Here is the back story. Over the winter my cousin laid my FXD down, he broke his leg, bike wasnt in terrible shape, it sat for a bit (hes like 11 hrs from me) the only real damage was the handlebars and a small dent on the right side of the tank. I was just going to slap it together to get it back on the road but i just finished some mods on my fatboy over the winter so im in no rush at this point. The fxd has about 25k miles on it so it has its fair share of seepage and other things that show its age. Once i started digging into it, i found myself going deeper and deeper. Finally i just said screw it, im going all of the way. I know a 2002 fxd is just going to be a labor of love but thats why im doing this build.

This will be a slow build as im not in a huge rush but i know how easy it is to back burner something like this. I am also mechanically inclined enough to know my way around tools and wrenching but have never messed with motorcycles before outside of basic repairs or mods (ive never been in an engine or transmission of a bike). But im sure im going to run into stuff that hangs me up.

Im not 100% sure on the look i want to go with just yet as im trying to go with the flow of things at the moment. I plan on going through the engine and gear box with some mild power upgrades (open to suggestions on mods everyone likes) But i do have a couple of question moving forward. I do have a shop manual for reference.

- Are there anythings as far as common issues or problems that anyone has experienced with FXD builds that would be helpful to know up front?

- What are some things you guys have done that you like or dont like?

Thats it for now. Here are some pics of the bike pre wreck and then some progress of everything so far.










 
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Old May 13, 2020 | 04:51 AM
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Very cool and welcome back.
The list for potential Dyna mods goes on and on....
There’s so many different bikes and riders with their own flavor of how to do it here that I’m sure you’ll end up with something you like. The knowledge base here is incredible and has been most valuable.



Following.
 

Last edited by brownie4412; May 13, 2020 at 04:55 AM.
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Old May 14, 2020 | 12:09 PM
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One for sure to inspect are the base gaskets, as they have a tendency to leak. If changing out, Cometic makes a good base gasket. Important to ensure the mating surfaces are even - be careful when removing the old base gasket if you're scraping it off.
 
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Old May 20, 2020 | 03:58 AM
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So I had to be out of town for a bit but was back in town this week but got back and made some small progress.

also now with covid19 slowing a bit would love to meet some people in my area who are into bikes as I’ve only been in NW Ga for a few years. Most of my wrenching buddies are in south Florida. So anyone in or around the Dalton GA area or Chattanooga Tennessee area let me know and we can try and get together. Here are some recent pics. And some pics I have found as motivation lol.







 
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Old May 20, 2020 | 07:51 AM
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You'll notice during tear down that the Dyna drivetrain (engine, trans, primary, final drive, rear suspension) is set up quite different from a softail. Swinger hangs off the trans. Engine and trans is only held in the frame by two rubber mounts and a little cross link on top. Getting everything aligned and stabilized can be a chore. There are many threads on these topics.

Dyna wobble...
 
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Old May 20, 2020 | 08:07 AM
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Originally Posted by Escapeordinary
So I had to be out of town for a bit but was back in town this week but got back and made some small progress.

also now with covid19 slowing a bit would love to meet some people in my area who are into bikes as I’ve only been in NW Ga for a few years. Most of my wrenching buddies are in south Florida. So anyone in or around the Dalton GA area or Chattanooga Tennessee area let me know and we can try and get together. Here are some recent pics. And some pics I have found as motivation lol.
Dalton is just a hair out of the way for me. I'm in Cumming, GA, about 1.5-2 hours away. I've been here for almost 3 years, and don't really know anyone else that rides. I'd be down for something different than the run to Dahlonega.
 
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Old May 27, 2020 | 09:04 AM
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Originally Posted by Harleywashboy
Dalton is just a hair out of the way for me. I'm in Cumming, GA, about 1.5-2 hours away. I've been here for almost 3 years, and don't really know anyone else that rides. I'd be down for something different than the run to Dahlonega.
Yea sounds good bud. Sorry for late reply. got busy for a bit. My fatboy is up and going so i would be down anytime. My cell is 352-454-8167 Name is joey. Shoot me a text when you have a moment so we can connect and ride.
 
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Old May 27, 2020 | 09:31 AM
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Alright, ive been gone from the forum for a couple of weeks. But i have been making progress, although slow lol. I was right at 25k miles when i started on this. Kind of glad i decided to go all the way with this build. The pistons had quite a bit of carbon build up, and when i pulled the cam cover off i saw a piece of plastic from the cam chan tensioner had broken off. And the bottom end has some slight seepage and the place where the halves meet. So here is where im at.

So im at the point in the tear down where im not really in any rush so i figured i should stop to post progress and ask some questions.

What kind of headaches if any that are not noticeable from the shop manual? (ive never been this deep lol)

For the engine i would like to only replace parts that are worn or damaged but i want to replace them with upgraded parts related to durability and performance. So if anyone has or could point me in the direction on parts and experiences with said parts. or a link to a build that you or someone else has done that is in line. Not looking for a power monster and im more of if it aint broke dont fix it kind of guy but if im in there and i should replace it because im there i dont mind or if its broken or worn and needs to be replace i dont mind upgrading it either.

I still need to get the gear box of the frame and the rest of the wiring. So any tips or trics on that would be much appreciated.

Finally here are some pics, mostly taken along the way for fun.







 
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Old May 27, 2020 | 09:32 AM
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Oh and tools. What are the special tools i have to have and what can i get away with fabricating or getting off with a screwdriver and BFH hahaha.
 
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Old May 27, 2020 | 08:54 PM
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Going with gears? Or staying with the hydrolics? Port and polish? Please stay with the white walls though.... Looked good with the green.

Looking forward to your thread....
 
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